Construction set for constructing a user-definable apparatus

ABSTRACT

A construction set for constructing a user-definable apparatus. for example a robot, is provided with one or more construction set components. The components may include components that are reconfigurable into other construction set components, and that have at least one demarcation defining adjacent segments thereof. The demarcations facilitate reconfiguration of the construction set components to produce other construction set components. The construction set may include an electromechanical drive assembly having an integrated speed control and operable to receive interchangeable. non-circular drive shafts. The electromechanical drive assembly may be configured to attach to and self-align relative to other construction set components. One or more of the components may be provided with openings through which the non-circular drive shafts may rotate. The drive shaft may be locked in relation to openings of components that allow the drive shaft to rotate via a lock plate. A bearing plate may also be included.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application for patent claims the benefit of priority from, andhereby incorporates by reference the entire disclosures of co-pendingU.S. Provisional Application for Patent Ser. No. 60/345,791, filed Dec.31, 2001, and U.S. Provisional Application for Patent Ser. No. ______,filed Dec. 31, 2002, entitled “Construction Set Having ComponentsDesigned to be Altered for Constructing a User-Definable Apparatus”.

BACKGROUND OF THE INVENTION

1. Technical Field of the Invention

The principles of the present invention generally relate to aconstruction set, and, more specifically, but not by way of limitation,to a construction set having construction set components designed to bealterable for use in constructing a user-definable apparatus.

2. Description of Related Art

The original erector set was filed for patent in 1901 and issued in1906. Since that time, erector sets have more or less remained the same.The erector set generally includes fixed sized parts having fixedgeometry and fixed coupling locations. The erector set includes partsthat have circular holes that are utilized to couple various mechanicalparts together. The erector set has and continues to be generallyutilized as a toy for children to construct structures that typicallyare incapable of handling dynamic stresses and loads. For example, astructure constructed from the erector set is typically incapable ofbeing utilized to perform specific tasks that include heavy lifting.

The original erector set elements, while useful in terms of producingstructures of fixed shapes and sizes, do not allow for atypical shapesand sizes of structures. One reason is that the components include holeslocated on the half pitch spacing. A second reason that atypical shapesand sizes of structures are prevented includes a limited number ofstructural elements or parts provided in a set and, therefore, a limiteddesign of structures are capable of being formed. Additionally, theerector set does not include a wide variety of coupling elements toprovide structurally sound, moveable joints for the structural elements.Further yet, the parts provided in the erector set typically areincapable of easily being reshaped and/or resized beyond theiroriginally provided form.

Newer erector sets and add-ons to the original erector set provide formotors that may be utilized to add functionality to the structures thatare created. However, the motors that are provided are generally notoverly useful due to the power of the motors being low and thestructural integration between the motor and the structural elementsbeing inadequate. The motors that are provided generally have limitedmotion control (e.g., fixed speed and limited torque range). Inaddition, the motor provided typically includes a round shaft extendingfrom the motor, where a set screw is generally required to couple theshaft to a mechanical element. Alternatively, a D-shaped shaft isprovided with the erector set. However, the D-shaped shaft isproblematic in that coupling the shaft to the mechanical elementsrequired the use of additional structural coupling components. Also,both of these shaft types are problematic in that transferring torque ofany magnitude is difficult to impossible simply because of interfacingcapability between the shaft and structural elements. Therefore, dynamicloads and stresses of more than insignificant levels result in an utterfailure of the drive capability of the motor.

In addition to the motor shaft coupling problems, the coupling of themotor to the structural elements provided in the erector set isproblematic due to the motor housing not having adequate structuralelements. Generally, those who want to attach the motor to thestructural elements have to produce an ad hoc coupling structure. Inother words, conventional erector sets do not provide an adequate numberand type of coupling components for a motor housing to be connected orfastened to a structure. Because of the heretofore mentioned problems ofthe erector components lacking the ability to handle dynamic loads andstresses, attaching a motor to a conventional erector set structure, theoverall structure tends to collapse and fall apart upon the occurrenceof a dynamic load or stress of even minor magnitude. The user istherefore forced to reconstruct the structure on a frequent basis.Although gears, chains, and other translational devices are provided inconventional erector sets, the chains, for example, are inadequate forbeing utilized to drive loads of functional capacity.

Modern educational systems have begun to instruct students in the art ofbuilding dynamic structures, such as those used in robot competitions.In fact, governments have begun to require that science, physics, andmathematics classes include the use of robotic and mechanical devices todisplay practical aspects of theoretical principles. Because theeducational systems are required to produce these devices, and becauseof the failure of the erector sets in the past to address practicalimplementations of these types of structures in robotics, rapid machineprototyping kit that is not limited by fixed structural components,inadequate coupling components, low powered motors, non-dynamic capacitydrive systems, and structural components capable of forming dynamically,structurally sound structures is needed.

SUMMARY OF THE INVENTION

To overcome the problems of conventional erector or construction sets, aconstruction set that provides components that are designed to bealterable is provided to allow for construction of a user-definableapparatus. The construction set may include construction set componentsthat are designed to be altered by including demarcations, such asindentations, that define segments of the construction set component.Such construction set components may include bars, plates, and gussets.The demarcations may facilitate altering of the component to form atleast one different construction set component. By being able to producea different construction set component, the user may construct aninfinite number of apparatus from the construction set that includes thealterable components.

The construction set may include a variety of other construction setcomponents that provide for safely, rapidly prototyping a user-definableapparatus. In terms of safety, the components may have a configurationwith substantially non-sharp corners to substantially eliminate risk ofinjury to the user or objects. In one embodiment, the corners may bechamfered. Alternatively, the corners may be rounded. In terms ofcomponents for rapid prototyping, in addition to or in combination withthe construction set components including demarcations, the componentsmay include openings configured to produce substantially no sharp edgesin the event of the component being severed at the opening. Further, thecomponents may include slotted bars and angles to allow a user toconstruct an apparatus in non-regular spacing intervals. Additionally,gussets with various configurations and openings may be included in theconstruction set to allow for the user to form joints with structuralintegrity. Fasteners configured to extend through openings in thecomponents may be provided.

The construction set according to the principles of the presentinvention may also include a variable speed, electromagnetic driveassembly. The variable speed, electromagnetic drive assembly mayintegrate a motor and an H-bridge circuit. By having the H-bridgecircuit integrated with the electromagnetic drive assembly, constructionof the user-definable apparatus is both electrical and mechanicalsimplified. Further, the electromagnetic drive assembly of theconstruction set may include protrusion(s) that may be inserted at leastin part into an opening of a construction set component for alignmentpurposes.

The construction set according to the principles of the presentinvention may also include a non-circular drive shaft. The non-circulardrive shaft provides for torque transfer between construction setcomponents with substantially the same, non-circular mating openings orsockets. By having a non-circular shape mating opening, a set screw tosecure the non-circular drive shaft is eliminated. Further, by providinga drive shaft mating socket in the electromechanical drive assembly,significant complexity in mechanical torque transfer design iseliminated. Self-aligning bearings, in the form of a plate or otherwise,may be provided to allow for smooth rotation of the non-circular driveshafts passing through openings in construction set components.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the methods, apparatus, and systems ofthe invention may be obtained by reference to the following detaileddescription when taken in conjunction with the accompanying drawingswherein like reference numerals used throughout the drawings denote thesame or similar features.

FIG. 1 is an exemplary user-defined apparatus or structure constructedfrom components of a construction set that are capable of being alteredto form a different component;

FIGS. 2A-2E are exemplary representations of a component configured as abar designed to be alterable via indentations defining borders ofadjacent segments for use in constructing a user-defined apparatus, suchas that of FIG. 1;

FIGS. 3A-3E illustrate exemplary views of a component configured as aplate designed to be alterable via indentations and openings definingborders of segments for use in constructing a user-defined apparatus.such as that of FIG. 1;

FIGS. 4A and 4B illustrate exemplary components configured as ‘plus’gussets for use in constructing a user-definable apparatus, such as thatof FIG. 1;

FIG. 5 illustrates an exemplary component configured as a base plate foruse in construction a user-definable apparatus, such as that of FIG. 1;

FIGS. 6A-6B illustrate an exemplary bar-slide angle designed to bealterable to provide for multiple length components for use inconstructing a user-definable apparatus, such as that of FIG. 1;

FIG. 7 illustrates an exemplary component configured as an angle gussethaving slot openings for use in constructing a user-definable apparatus,such as that FIG. 1;

FIG. 8 illustrates an exemplary configuration of the angle gusset ofFIG. 7 being aligned with the bar of FIG. 2A;

FIGS. 9A and 9B illustrate exemplary components configured as an anglepivots having an arcuate slot opening for use in constructing auser-definable apparatus, such as that of FIG. 1;

FIG. 10 illustrates an exemplary configuration of the angle pivot ofFIG. 9 being coupled with a portion of the bar-slide angle of FIG. 6Aand the bar of FIG. 2A;

FIG. 11 illustrates an exemplary component configured as a switch diskhaving an arcuate slot opening for use in constructing a user-definableapparatus, such as that of FIG. 1;

FIG. 12 illustrates an exemplary component configured as a trigger foruse with the switch disk of FIG. 11;

FIG. 13 illustrates an exemplary configuration of the trigger of FIG. 12in association with the switch disk of FIG. 11 along with a non-circularshaft for rotating the trigger with respect to the switch disk;

FIGS. 14A-C illustrate exemplary components configured as locking barsoperable to be used in constructing a user-definable apparatus, such asthat of FIG. 1;

FIGS. 15A and 15B illustrate an exemplary configuration of the lockingbar of FIG. 14 being coupled to the bar of FIG. 2A and shaft of FIG. 13;

FIGS. 16A and 16B illustrate an exemplary component configured as abearing or bushing plate for use in constructing a user-definableapparatus, such as that FIG. 1;

FIGS. 17A and 17B illustrate exemplary configurations of the bearingplate of FIG. 16A being coupled to the bar of FIG. 2A and shaft of FIG.13;

FIGS. 18A and 18B illustrate the left and right side of a wheel withhubs having circular and non-circular openings disposed therein,respectively, for use in constructing a user-definable apparatus, suchas that of FIG. 1;

FIGS. 19A and 19B illustrate an exemplary roller for use in constructinga user-definable apparatus, such as that of FIG. 1;

FIGS. 20A-20C illustrate an exemplary gear having a non-circular openingfor use in coupling with the shaft of FIG. 13 in constructing auser-definable apparatus, such that of FIG. 1;

FIGS. 21A and 21B illustrate an exemplary chain for use in constructinga user-definable apparatus, such as that of FIG. 1;

FIG. 22 illustrates multiple gears of FIG. 20A being driven by the chainof FIGS. 21A and 21B;

FIG. 23 illustrates an exemplary configuration of multiple bars of FIG.2A being spaced by spacers with fastener openings for use inconstructing a user-definable apparatus, such as that of FIG. 1;

FIGS. 24A-24I illustrate an exemplary housing of an electromechanicaldrive assembly, such as a motor or servo, for use in constructing auser-definable apparatus, such as that of FIG. 1;

FIG. 25 is an exemplary flow chart for configuring the housing bodyhaving aperture engagement member(s), such as that shown in FIG. 24A,with an electromechanical drive;

FIG. 26 is an exemplary block diagram providing an electricalarchitecture for controlling speed and direction of an electromechanicaldrive for use in constructing an apparatus from components of aconstruction set;

FIG. 27 A is an exemplary electronic schematic for providing thevariable speed and direction control provided by the block diagram ofFIG. 26;

FIG. 27B is an exemplary mechanical schematic for limiting current tothe electromechanical drive based on an over-current and/orover-temperature condition thereof;

FIG. 28 is an exemplary flow diagram for controlling theelectromechanical drive of the electromechanical drive assembly of FIG.24A for an electromechanical structure constructed using theconstruction set;

FIG. 29 is an exemplary flow chart for converting a non-variable speedelectromechanical drive assembly to an electromechanical drive assemblyfor use with a construction set for constructing an electromechanicalapparatus, such as that of FIG. 1;

FIGS. 30A and 30B illustrate an exemplary user-defined apparatus withoutand with a controller, respectively, for controlling operation of theapparatus via electromechanical drive assemblies of FIG. 24A;

FIG. 31 is an exemplary break clamp for use in reconfiguring a componentdesigned to be alterable for use in constructing a user-definableapparatus, such as that of FIG. 1;

FIG. 32 is another tool for use in constructing a structure, such asthat of FIG. 1, with a construction set according to the principles ofthe present of the present invention;

FIG. 33 is an exemplary flow chart describing distribution of completeconstruction sets having component(s) designed to be alterable andseparate component(s) designed to be alterable for use in replacing thealterable components as desired in constructing a user-definablestructure, such as that of FIG. 1;

FIG. 34 is an exemplary flow diagram for teaching project developmentlessons utilizing the construction set having components designed to bealterable, such as the bar of FIG. 2A, according to the principles ofthe present invention; and

FIG. 35 is an exemplary embodiment for teaching production cycle projectdevelopment utilizing a construction set having at least oneconstruction set component designed to be alterable for constructing auser-definable apparatus 100, such as that of FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

A construction set includes construction set components (“components”)for use in constructing an apparatus. One embodiment of a constructionset according to the principles of the present invention provides for atleast one construction set component designed to be alterable to enablereconfiguration for use in constructing a user-definable apparatus orstructure. A construction set component is a component provided in aconstruction set for constructing an apparatus.

A user-definable apparatus is one in which the user of the constructionset may define a type of apparatus, for example, a robot versus a carversus a statue versus an airplane. By contrast, a non-user definableapparatus is one that a designer and/or manufacturer of a constructionset predetermines and provides components intended to build only thenon-user definable apparatus. For example, a model kit for constructingan airplane (e.g., B-52 bomber) would not be considered a user-definableapparatus since the only type of apparatus intended to be constructedwith the components of that model kit is the B-52 bomber airplane. Thedesigner and/or manufacturer may include optional components, forexample, gun turrets, missiles or bombs, and decorative features, suchas decals; however, the resulting apparatus is still an airplane. Whileone apparatus that can be built with a construction set for constructinga user-definable apparatus may be an airplane, because of versatility ofthe component(s), many other types of apparatus may be constructed. Inanother example, a train or slot car set may come with track pieces withwhich a user may configure different tracks, but the track is a non-userdefinable apparatus because it remains a track no matter how it isconfigured. A user-definable apparatus does not preclude one that adesigner and/or manufacturer of a construction set has predetermined andprovided components to build the apparatus if the components areintended to be used to construct different apparatus of the same ordifferent type. For example, a construction set for constructing auser-definable apparatus may be provided with instructions to build oneor more apparatus and the user may define and build different apparatusof the same or different type.

A component designed to be alterable is a component having at least onedemarcation, indentation, or other user-identifiable feature thatenables the component to be altered or reconfigured into one or moredifferent components. The altering or reconfiguring may include bending,separating, severing, cutting or otherwise changing the permanent ornon-permanent form (see, for example, FIGS. 2A-2B) of the componentdesigned to be altered. A component that may be altered (e.g., bent orcut) without having a predefined demarcation or other identifiableindicia or structural identifier for altering the component is not acomponent designed to be alterable according to the principles of thepresent invention.

The principles of the present invention enable building a user-definableapparatus with the component designed to be alterable and othercomponents configured to engage feature(s) of the components designed tobe alterable. In one embodiment, the component designed to be alterablemay include openings or holes of different sizes to enable a drivecomponent, such as a non-circular shaft, to engage an opening conformingto the size of the drive component or to rotate without interferencewithin an opening larger than the external profile of the drivecomponent. The construction set may further include electromechanicalcomponents, such as an electromechanical drive assembly, that may beconfigured to move the components. In one embodiment, theelectromechanical drive assembly may have a drive port or socket beingnon-circular in profile and operable to receive and drive or translatemotion to a non-circular shaft at least partially conforming to theinternal profile of the socket. By using a non-circular shaft, a highertorque may be applied to a mechanical component being rotated by thenon-circular shaft than by a circular shaft, which requires use of aset-screw or other locking element. Still yet, other componentsconfigured to be coupled to the components designed to be alterable andeither engage or support rotation of the non-circular shaft may beprovided to further provide flexibility in construction of theuser-definable apparatus. The construction set according to theprinciples of the present invention may be utilized by teaching and/orother organizations in teaching students or participants of an event inreal-world design management because the construction set includescomponents designed to be alterable for use in constructing auser-definable apparatus. In the teachings, the students learn about,but are not limited to, of optimizing material usage, managing cost,inventory, design, and manufacturing issues. Problem solving skills arefurther developed by users of the construction set according to theprinciples of the present invention.

Mechanical Components

FIG. 1 is an exemplary user-defined apparatus or structure 100constructed from components of a construction set that are capable ofbeing altered to form a different component. As shown, the user-definedapparatus 100 is electromechanical in that a controller 102 is used tocontrol electromechanical drives or motors 104, which, in turn, driverotational components, such as wheels 106 that support the mechanicalstructure configured by components of the construction set that aredesigned to be alterable. As shown, the user-defined apparatus 100 iskinematic in that the structure incorporates provisions for movement, byinternal or external sources, of at least one component of thestructure. The user-defined apparatus 100 may be of a scale suitable foroperation on the top of a table, or alternatively, smaller or larger.Because the components are designed to be alterable, the user-definedapparatus 100 produced to perform a function by a user of theconstruction set is capable of being configured completely differentusing the same components designed to be alterable provided in theconstruction set according to the principles of the present invention.

FIG. 2A illustrates an exemplary bar 200 that is designed to bealterable for use in constructing the user-defined apparatus 100. FIG.2A is a front, top perspective view showing the bar's 200 left edge. Theappearance of the bottom surface, rear edge and right edge may besubstantially the same. The bar 200 has a predetermined length that istypically longer than a length used in constructing a user-definablestructure. Because the bar 200 is designed to be alterable (e.g., cut,bent, or otherwise reconfigured), the bar 200 may be shortened inlength, bent, or otherwise altered in dimension according to the desiresof the user of the construction set.

The bar 200 includes multiple segments 201 extending along the length ofthe bar 200. The segments 201 of the bar 200 are shown to besubstantially identical. However, it should be understood that thesegments 201 may have different shapes and/or configurations. Thesegment 201 includes an outside edge 202 and an opening 204. The outsideedges 202 are designed to substantially prevent injury, such as scrapingor cutting, to a user by providing for dulled corners and obtuse anglesat the corners of the bar 200. Alternatively, the corners may be curvedor have another shape designed to substantially prevent injury to auser. As shown, the corners of the bar 200 are chamfered 206 to avoidhaving a sharp corner. A sharp corner is one which is likely to scratchor cut skin or other material. A sharp corner typically has an acuteangle or burr as understood in the art.

The opening 204 in the segment 201, as shown, is substantially shaped asa square. The opening 204, however, may have another polygonal shape,such as a triangle, hexagon, rectangle, or circular, curved, elliptical,irregular, or otherwise to receive coupling or fastening elements. Aswill be discussed in more detail below, the openings 204 are adapted toreceive a drive shaft (such as shaft 1302 of FIG. 13) and allow thedrive shaft to rotate freely therein. In one embodiment, the openings204 are spaced at regular intervals D (FIG. 2B). The regular intervalsmay be one-half inch spacing between the center of the openings 204.

Demarcations may be provided on the bar 200 that define the borderbetween adjacent segments 201. The demarcation may be represented by oneor more indentations 208 a-208 b (collectively 208), grooves, scores,perforations, or other features known in the art to define a borderbetween adjacent segments 201. At least one demarcation may reduceresistance to bending of the bar 200 along or extending substantiallybetween the demarcation(s). Additionally, at least one demarcation maysubstantially prevent a sharp corner from forming in the event that thebar 200 is separated, severed or bent at the demarcation.

FIG. 2B provides an exemplary portion of the bar 200 magnifying thefeatures thereof. The indentations 208 are shown as being substantiallyopposed along the outside edge 202 of the bar 200. The indentations 208being substantially opposed define a border between adjacent segments sothat the bar 200 may be altered along the plane of the opposedindentations 208. The indentations 208 may alternatively and/oradditionally be disposed on the top and bottom surfaces 209 of the bar200. In one embodiment, the indentations 208 may be scores on the topand bottom surfaces of the bar 200.

FIG. 2C depicts an enlarged section of the bar 200 having thesubstantially opposed indentations 208. Demarcations 214 a and 214 b(collectively 214), which extend between the indentations 208, may beutilized to facilitate altering the bar 200 in relation thereto. Thedemarcations 214 may be a score, perforation, line, groove, print, orother insignia that facilitates altering the component. It should beunderstood that the demarcations 214 may be associated with otherdemarcations (e.g., indentations 208) or be independent of otherdemarcations. The indentations 208 include diagonal edges 210substantially in a V-shape. Further, radius portions 212 a and 212 b(collectively 212) disposed between the diagonal edges 210 for each ofthe indentations 208 a and 208 b, respectively, are included. The radiusportions 212 have approximately the same or a slightly larger diameterthan a width of a cutting tool anticipated to be used to sever the bar200.

Normally, when a piece of material is severed, for example with tinsnips or shears, edge portions of the material tend to deform outwardfrom the plane of the edge. The material that deforms outward forms asharp corner, and in many cases, forms burrs that extend outward fromthe edge surfaces of the material. The shape of the indentations 208reduces the amount of material available to extrude outside the existingshape of the bar 200, thereby minimizing the formation of burrs when thebar 200 is severed. Further, the indentations form chamfered cornerswhen the bar 200 is severed, thereby eliminating a sharp corner thatwould form without the indentations 208. As a result when segments 201are severed, the resulting pieces have substantially no burrs or sharpcorners.

FIG. 2D illustrates a resulting separation of two adjacent segments 201substantially between the indentations 208. The resulting bar segmentsinclude new edges 216 formed along the line of separation between theindentations 208 having separation corners 218 with substantially nosharp artifacts. It should be understood that the indentations 208 withthe radius portion 212 may be configured with other shapes, such ascurves, that result in substantially no sharp corners being formed andconform to the principals of the present invention.

FIG. 2E illustrates an exemplary bar 200 having been altered to form abend between the indentations 208 to result in a different component(i.e., a component that has been altered in size, shape, or otherdimensions). A border 220 between the segments 201 shows that the bar200 may be reconfigured or plastically deformed substantially withoutbreaking due to, at least in part, the material of the bar 200. In oneembodiment, the material of the bar 200 is metal that is plasticallydeformable without substantially breaking. The metal may be cold rolledsteel, which provides good altering properties and is cost effective forproducing components to be utilized for the construction set.Alternatively, the material of the bar 200 may be formed of a plasticthat allows for altering or bending without substantially breaking andcapable of maintaining a reconfigured shape.

FIG. 3A shows an exemplary plate 300 designed to be alterable for use inconstructing the user-definable apparatus of FIG. 1. FIG. 3A is a front,top perspective view showing the plate's 300 left edge. The appearanceof the bottom surface, rear edge and right edge may be substantially thesame. The plate 300 includes segments arranged in rows r₁-r₅ and columnsc₁-c₂₅. Similar to the segments 201 of the bar 200, openings 204 aredisposed therein. Each opening 204 is shown to be shaped as a square,but may be any other shape operable to be coupled to other componentsand/or fasteners of the construction set. The openings 204 may be shapedor oriented differently (e.g., square and hexagonal) on the plate 300.As above, the openings 204 are adapted to receive a drive shaft (such asshaft 1302 of FIG. 2) and allow the drive shaft to rotate freely thereinand also adapted to receive a fastener for joining the plate 300 toother construction set components. In one embodiment, the openings 204are spaced at regular intervals. While the segments 201 are shown to besubstantially identical along the plate 300, it should be understoodthat the segments may be configured to be different along certain areasor regions and have a variety of orientations and/or configurations.Indentations 208 are substantially opposed along a plane between boththe rows and columns to define borders between a grid of segmentsthereof, respectively. Additionally, to substantially prevent injury tousers or other materials, chamfers 206 are disposed on the corners ofthe plate 300.

Disposed substantially between a set of substantially opposedindentations 208 are openings 302 being substantially diamond-shaped.The openings 302 are substantially squares that are alignedapproximately 45 degrees in relation to the openings 204 disposed in thesegments 201. Openings 302 function similar to indentations 208, in thatthey are configured to reduce the amount of material available forextrusion when severed between openings 302, for example with clippers,thereby substantially preventing the formation of burrs. Furthermore,smaller pieces severed from the 300 will resultantly have chamferedcorners. In addition to being configured to substantially prevent theformation of burrs and sharp corners, the openings 302 can be sized toreceive a component, such as the drive shaft 1302 of FIG. 13, andprevent rotation of the component relative to the opening 302. It isimportant to note that the component engaged by the diamond-shapedopening 302 may pass and rotate freely through the segment opening 204.

The opening 302 may be substantially regularly spaced between thesegments 201 of the plate 300. Alternatively, the openings 302 may bespaced in another configuration based on different desires of thedesigner to enable a user to separate and/or alter the plates 300. Itshould be further understood that the openings 302 may have a shapeother than a diamond, such as a hexagonal, octagonal, or other shapethat substantially prevents sharp corners from being formed uponseparation of adjacent segments 201. Accordingly, the opening 302 beingdiamond or other polygonal shape includes a radius portion, such as theradius portion 212, at the intersection of the internal edges so as tosubstantially prevent the formation of sharp corners. The openings 302reduce bending strength along the axis of the openings 302. Furthermore,the openings 302 provide an additional benefit when bending two or moreadjacent edges of the plate 300. As seen in FIGS. 3C-3E, when a segment201 is removed at a corner of the plate 200 and the edge segments 201are bent out of the plane of the plate 200, the openings 302 provide apre-made bend relief as commonly used in the art of sheet metalfabrication. A bend relief involves removing a small amount of metal atthe point at which two bend lines meet. Without a bend relief, thematerial at the two bends would contact and deform at the point at whichthey meet. The bend relief is created by simply removing the material(e.g., metal) at which the bends collide.

Because the plate 300 includes demarcations, such the indentations 208and openings 302, it may be said that the plate is designed to bealterable by the user to form a different component of the constructionset. The different component may be any component that has a differentdimension and/or shape than that of the plate 300. The plate 300 may becomposed of a material to enable reconfiguration. In one embodiment, thematerial of the plate 300 may be metal, such as cold roll steel, thatallows for plastically bending without breaking. The material mayfurther provide for cutting and/or separation by a method other thancutting. In another embodiment, the material of the plate 300 may be aplastic material that may be bent and retain the bent shape. FIG. 3Bshows a detail view of the plate 300 depicting the indentations 208 andopenings 302 that enable alteration of the plate 300 and prevent sharpcorners from being formed. Accordingly, the openings 302 being disposedto define borders between adjacent segments 201 may operate asdemarcations irrespective of the indentations 208.

FIG. 4A is an exemplary component shaped as a plus gusset 400 a for usein constructing a user-defined apparatus, such as that of FIG. 1. FIG.4A is a top view of the plus gusset 400 a. The appearance of the backside is substantially similar. As shown, the plus gusset 400 a is formedof a single piece of material and includes rectangular openings 204being substantially square and having a regular spacing. In oneembodiment, the spacing substantially matches the spacing of theopenings 204 of the bar 200 and plate 300. It should be understood,however, that the openings 204 may have spacings other than regular andshapes other than squares. The corners of the plus gusset 400 a havechamfers 206 to avoid having sharp corners to substantially preventinjury or damage to users or materials that come in contact with theplus gusset 400 a.

FIG. 4B is an exemplary plus gusset 400 b designed to be altered and isthereby provided with demarcations 408. FIG. 4B is a front view. Theappearance of the bottom surface may be substantially the same. In theexemplary embodiment shown, the demarcations 408 may be indentations ina rectangular C-shape that is similar to the shape left when diamondshaped openings 302 of plate 300 (FIGS. 3A-3E) are cut. The demarcationsdefine segments 410 of the plus gusset 400 b and facilitate alterationof the plus gusset 400 b to make other construction set components. Forexample, the plus gusset 400 b may be formed into a T-shape by severingone segment 410 or into an L-shape by severing two adjacent segments410. Furthermore, the plus gusset 400 b may be bent into differentshapes. Either plus gusset 400 a or 400 b may be formed of metal that isplastically deformable without substantially breaking.

The plus gusset 400 a or 400 b may be utilized to facilitate coupling ofcomponents of the construction set, including those joined at rightangles. For example, the plus gusset 400 a or 400 b may be utilized atthe juncture of two bars 200 to increase the rigidity of the connectionand hold the bars 200 in fixed relation in forming a user-definedstructure, such as that of FIG. 1. The plus shape adds structuralstrength and versatility to a structure built by a designer. It shouldbe understood, however, that other shaped gussets having openings 204may be included in the construction set for constructing user-definablestructures according to the principles of the present invention.

FIG. 5 is an exemplary base plate 500 that is not designed to bealterable for use in construction a user-definable apparatus, such asthat of FIG. 1. FIG. 5 is a front view. The appearance of the bottomsurface may be substantially the same. Although the base plate 500 isnot designed to be alterable, the base plate 500 includes obtuse anglesfor corners 502 so as to have no sharp corners. The base plate 500 isoctagonal-shaped and may be used for a structural support on which auser-definable structure may be constructed. It should be understoodthat the base plate 500 may have other shapes to provide structuralsupport for construction of a user-definable structure.

The base plate 500 includes rows and columns of openings 204 that may bespaced in accordance with the spacing of the openings 204 of the bar 200and plate 300 so as to enable coupling therebetween. Rectangular orifice504 may be disposed substantially in the center of the base plate 500 toenable electronics or other mechanical components to be accessed orextend therethrough.

FIG. 6A illustrates an exemplary bar-slide angle 600 designed to bealterable to provide for multiple length components for use inconstructing a user-definable apparatus, such as that of FIG. 1. Thebar-slide angle 600 includes two substantially planar portions, a barportion 601 a-601 c (collectively 601) and a slide portion 602 a-602 c(collectively 602). Each bar and slide portion (e.g., 601 a and 602 a)are formed as segments 603 a-603 c having demarcations in the form ofindentations 208 being substantially opposed, although not in 180 degreerelation.

The bar portion 601 includes openings 604 disposed thereon. The openings604 are substantially rectangular in shape and have a spacing conformingto that of the spacing of the openings on the bar 200 and/or plate 300.It should be understood that the openings 604 may be other thanrectangular, but that the rectangular shape, as with the otherrectangularly shaped openings in the construction set, enablesadjustably positioning the bar-slide angle 600 in relation to anothercomponent of the construction set, such as the base plate 500, atpositions that depart from the grid pattern of the openings 204 whencoupling the bar-slide angle 600 to the other component. The openings604, as shown, are oriented with a longer dimension substantiallyperpendicular to the length of the bar-slide angle 600, but can beoriented in other directions. As with openings 204, the openings 604 canbe configured to receive fasteners and a drive shaft (such as the driveshaft 1302 of FIG. 13) and allow the drive shaft to rotate therein. Oneor more additional substantially rectangular slide openings 608 a-608 c(collectively 608) can be provided in the slide portion 602 and orientedsubstantially perpendicular to the orientation of the openings 604, thatis with a longer dimension substantially parallel to the length of thebar-slide angle 600. One or more additional side openings 610 can bedisposed adjacent a given slide opening in the slide portion 602 andoriented in the same or similar manner to openings 604, that is with alonger dimension perpendicular to the length of the bar-slide angle 600.As with the openings 604, the slide openings 608, and side openings 610can be configured to receive fasteners and a drive shaft (such as driveshaft 1302 of FIG. 13) and allow the drive shaft to rotate therein. Theside openings 610 may be rectangular or otherwise.

The bar-slide angle 600 can be formed of a single piece of material andhas an angle extending between the bar portion 601 and slide portion 602along a common edge 605. The angle is shown to be 90 degrees, but couldbe any other angle. The bar-slide angle 600 may be formed of metal thatis plastically deformable without substantially breaking.

The bar-slide angle 600 is composed of the three segments 603 a-603 chaving different lengths. The bar-slide angle segment 603 a includes tenopenings 604 in the bar portion 601 a; the bar-slide angle segment 603 bincludes fifteen openings 604 in the bar portion 601 b; and thebar-slide angle segment 603 c includes five openings 604 in the barportion 601 c. The number of openings 604 corresponds to the relativelength of the segments 603. Accordingly, slide openings 608 a-608 cdisposed in the respective slide portions 602 a-602 c of the barportions 601 a-601 c also extend different lengths. Openings 610disposed on the slide portions 602 a and 602 b provide locking abilityfor the longer bar-slide segments 603 a and 603 b in construction. Byarranging the three segments as shown, it is possible to producebar-slide angles 600 having bar sections 601 with five, ten, fifteen,twenty, twenty-five and thirty openings 604 by cutting or separating thebar-slide angle 600 in relation to the indentations 208. For example, toproduce a bar-slide angle 600 with twenty openings 604 (and thecorresponding length thereof), one would sever the portion of thebar-slide angle 600 having ten openings thereby retaining the portionshaving five openings 604 and fifteen openings 604 (i.e., 5+15=20). Toproduce a bar-slide angle 600 with twenty five openings 604, one wouldsever the portion of the bar slide angle 600 having five openings 604.Clearly, to produce a bar-slide angle 600 with five, ten or fifteenopenings 604, one need only sever the segment containing the correctnumber of openings 604. It should be noted that the principle ofsegmenting a component, such as that of the bar-slide angle 600, may beapplied to other components of the construction set.

FIG. 6B provides a detail view of the intersection between bar portion601 a and 601 b. As shown, indentation 208 a is disposed substantiallyin opposed relation to indentation 606. The indentation 606, can beshaped different from the indentation 208 a, but still operable toprovide for cutting along the intersection between the bar portion 601 aand 601 b. Accordingly, the opening 608 is disposed on the bend (commonedge 605) to enable the user to separate the bar-slide angle segments603 with relative ease. The separation may be performed utilizing a toolthat cuts between the indentation 208 a and opening 606.

FIG. 7 is an exemplary angle gusset 700 having slot openings for use inconstructing a user-definable apparatus, such as that of FIG. 1. Theangle gusset 700 includes a first substantially planar portion 702coupled to a second substantially planar portion 704 along an edge 706.The angle gusset 700 can be formed from a single piece of material bentalong the edge 706 to form a 90 degree angle between the first andsecond portions 702 and 704. To provide strength, in one embodiment, theangle gusset is formed of metal, such as cold rolled steel or othermaterial that is plastically deformable without substantially breaking.

As shown, a first slot opening 708 is disposed along the first portion702 and a second slot opening 710 is disposed along the second portion704. The slot openings 708 and 710 are oriented substantiallyperpendicular in relation to one another. The first slot opening 708 issubstantially centered about the midpoint of the second slot opening710. The respective slot openings 708 and 710 are sized to allowcoupling to other components of the construction set via fasteners, andcan also, one or both, be configured to receive a drive shaft, such asdrive shaft 1302 of FIG. 13, and allow the drive shaft to rotate freelytherein. Although shown in a bent configuration, the angle gusset 700may be flat, such that both the first and second portions 702 and 704are in the same plane. Alternatively, the angle gusset 700 may have anangle between the first and second portions 702 and 704 other than 90degrees. The slot openings 708 and 710 are aligned to allow coupling ofother components on non-half pitched spacings to allow a user to designuser-definable structures in a more flexible manner.

In accordance with the principles of the present invention, the anglegusset 700 includes chamfers 206 to substantially eliminate sharpcorners. Additionally, the first portion 702 utilizes obtuse anglecorners 712 to prevent having a sharp corner, thereby substantiallypreventing risk of injury for a user. It should be understood thatcurves or other non-sharp corners may be utilized rather than havingangled corners via the chamfers 206 or otherwise.

FIG. 8 is an exemplary configuration 800 of the angle gusset 700 of FIG.7 being aligned with the bar 200 of FIG. 2A. As shown, the angle gusset700 may be aligned with the openings 204 of the bars 200. Because theslot opening 710 does not require regular or non-regular spacing,orientation of the perpendicular bar 200 coupled to the slot opening 708of the angle gusset 700 may be aligned on a variable-pitch spacing withrespect to the bar 200 coupled to the slot opening 710 of the anglegusset 700. Accordingly, the angle gusset 700 may be coupled to othercomponents (e.g., plate 300 and base plate 500 for constructing auser-definable structure). To engage the angle gusset 700 with othercomponents, fasteners may be utilized to secure or allow sliding of thecomponents with respect to the angle gusset 700. The angle gusset 700can be formed from metal or other material that is plasticallydeformable without substantially breaking.

FIG. 9A is an exemplary angle pivot plate 900 a having an arcuate slotopening 902 for use in constructing a user-definable apparatus, such asthat of FIG. 1. FIG. 9A is a front view. The appearance of the bottomsurface may be substantially the same. The angle pivot plate 900 a, asshown has one arcuate slot opening 902 and is substantially planar. Inone embodiment, the angle pivot plate 900 a and 900 b may be formed froma material that is plastically deformable without substantiallybreaking. The arcuate slot opening 902 is disposed substantially about acenter point and can have a substantially constant radius. Additionalarcuate slot openings may be proved adjacent the arcuate slot opening902. See, for example, the exemplary angle pivot plate 900 b of FIG. 9B,which, as shown, has two arcuate slot openings 902 and 910. FIG. 9B is afront view. The appearance of the bottom surface may be substantiallythe same. Providing two arcuate slot openings 902 allows mounting anelectromechanical drive assembly (such as electromechanical driveassembly 2402 of FIG. 24A) to one slot with the drive shaft extendingthrough the adjacent slot to thereby allow angular adjustably of theelectromechanical drive assembly relative to the angle pivot plate 900b. Such a combination is well suited for use as a compact drive linetensioner.

An arcuate edge 904 is disposed on the opposite side of the center pointof the arcuate slot opening 902. Further, the angle pivot plate 900 maybe configured to have a first edge 906 a and a second edge 906 b thathave a substantially perpendicular orientation therebetween. It shouldbe understood, however, that other angles may be provided for the anglepivot plate 900. The arcuate slot opening 902 may have indicia 908 thatindicate angle about the arc of the slot opening 902. Further, openings204 being sized and shaped substantially similar to the openings 204 ofother components may be disposed between the arcuate slot opening 902and the center point thereof to enable the angle pivot plate to becoupled to another component of the construction set for constructing auser definable apparatus. As shown, the angle pivot plate 900 has anopening 204 at the center point of the arcuate slot opening 902, andthree openings 204 substantially equidistant between the center pointand the arcuate slot opening 902. The openings 204 can be substantiallynon-circular, and as shown are substantially square with an edge alignedwith an edge of the angle pivot plate 900. As with other components ofthe construction set, the angle pivot plate 900 can be made of out metalthat is plastically deformable without substantially breaking.

FIG. 10 is an exemplary configuration 1000 of the angle pivot plate 900of FIG. 9 being coupled with the bar-slide angle 603 a of FIG. 6A andthe bar 200 of FIG. 2A. As shown, the bar 200 is coupled to an opening204 at or near the center point of the arcuate slot opening 902. Theopening 204 may be spaced consistent with the spacings of the openings204 of the bar 200. In one embodiment, the arcuate slot opening 902 isdisposed at multiple (e.g., double) spacings from the opening 204 at thecenter point of the arcuate slot opening 902 to enable a fastener 1002extending through the opening 204 of the bar 200 and extending throughthe arcuate slot opening 902 to travel through the arcuate slot openingto allow the bar 200 to pivot relative to the angle pivot plate 900,accordingly.

The angle pivot plate 900 is further coupled to the ten-openingbar-slide angle segment 603 a of the bar-slide angle 600. By couplingthe slide opening 608 a of the bar-slide angle segment 603 a, the anglepivot plate 900 may be positioned at any location along the slideopening 608 a to provide flexibility in constructing the user-definablestructure. The position of the bar 200 relative to the bar-slide anglesegment 603 a is infinitely adjustable within the range of the arcuateslot opening 902. The fastener 1002 is shown to be a bolt having a locknut (not shown) operable to be tightened via a hex driver. It should beunderstood that any other fastener operable to couple the bar 200 to theangle pivot plate 900 via the openings 604 on the bar portion 601 a oropening 610 on the slide portion 602 a of the bar-slide angle segment603 a.

FIG. 11 is an exemplary switch disk 1100 having an arcuate slot opening1102 for use in constructing a user-definable apparatus 100, such asthat of FIG. 1. FIG. 11 is a front view. The appearance of the bottomsurface may be substantially the same. An opening 302 is disposedsubstantially in the center of the switch disk 1100. In one embodiment,the opening 204 is substantially square having approximately the samesize as the openings 204 of the bar 200 or other component of theconstruction set. The slot opening 1102 may be substantially arc shapedand disposed radially about the opening 204. The slot opening 1102 canbe configured to receive fasteners and a drive shaft, such as driveshaft 1302 of FIG. 13) and allow the drive shaft to rotate freelytherein. In one embodiment, the opening 302 can be a shaft engagingopening having an inner profile substantially the same size and shape asthat of the outer profile of a shaft (see, for example, FIG. 13) forfixedly engaging the shaft to rotate the switch disk 1100.Alternatively, the opening 302 may be sized substantially the same asthe opening 204 to allow a shaft to rotate therein and to receive afastener for attaching the switch disk 1100 to another component of theconstruction set. Another opening 1104 may be disposed between the endsof the slot opening 1102 and the disposed at substantially the sameradius from the center of the switch disk 1100 as the slot opening 1102to receive fasteners for coupling the switch disk 1100 to othermechanical components of the construction set. The opening 1104 may becircular or have another shape to receive a fastener.

FIG. 12 is an exemplary switch trigger 1200 for use with the switch disk1100 of FIG. 11. FIG. 12 is a front view. The appearance of the bottomsurface may be substantially the same. The switch trigger 1200 is acomponent that includes two openings, a first opening 1202 at one endand a second opening 1204 positioned at a second end of the switchtrigger 1200. The second opening 1204 is positioned at a greaterdistance nom the second end than the first opening 1202 in relation tothe first end. The openings 1202 and 1204 are spaced to be aligned withthe opening 302 centrally positioned in the switch disk 1100 and thearcuate slot 1102 of the switch disk 1100. The first opening 1202 on theswitch trigger 1200 is adapted to be axially aligned with the opening302 of the switch disk 1100 and allow free rotation of a shaft extendingtherethrough. The second opening 1204 is adapted to receive a fastenerthat may be positioned through the arcuate slot 1102 of the switch disk1100.

FIG. 13 is an exemplary configuration 1300 of the switch trigger 1200 ofFIG. 12 in association with the switch disk 1100 of FIG. 11 along with ashaft 1302 being non-circular for rotating the switch disk 1100 withrespect to the switch trigger 1200. The switch disk 1100 may be rotatedby the drive shaft 1302 by interfacing with the opening 302 (see, FIG.11) to substantially operate as a fixed or variable earn, and may beused as a mechanical switch or in conjunction with an electrical switchand the like. By rotating the drive shaft 1302, the switch disk 1100rotates accordingly while the switch trigger 1200 may be set at apredetermined angle to operate as a mechanical switch as understood inthe art. It should be understood that the coupling of the switch trigger1200 to the switch disk 1100 may allow for a multitude of angularrotations of the switch disk 1100, and may provide for angularmeasurements through the inclusion of indicia (not shown) on the switchdisk 1100 or via electronic calibration.

FIGS. 14A-14C are exemplary lock plates 1400 a and 1400 b operable to beused in constructing a user-definable apparatus 100, such as that ofFIG. 1. As many of the components described above include openings 204that receive a drive shaft (such as drive shaft 1302 of FIG. 13) andallow the drive shaft to rotate within the opening, a lock plate 1400 aor 1400 b can be provided for attachment to the components to lock thedrive shaft in relation to the component. Accordingly, the lock plate1400 a includes at least one shaft engaging opening 302 that is sizedand shaped to engage a non-circular shaft 1302. FIG. 14A is a frontview. The appearance of the bottom surface may be substantially thesame. As shown, the shaft engaging opening 302 is substantially squareto engage a substantially square shaft 1302. Alternatively, the shaftengaging opening 302 may have any other non-circular shape to engage ashaft that is non-circular and prevent rotation of the shaft relative tothe opening 392 (e.g., example a flat surface that engages a flatsurface of the shaft). An opening 1402 may be disposed at each end ofthe lock plate 1400 a. The opening 1402 may configured to enable afastener to engage the lock plate 1400 a and another component having anopening (e.g., bar 200 with openings 204).

As shown in FIG. 14B, lock plate 1400 b has an insert 1404 that isinsertable into one or more than one of the openings 1402 and has ashaft engaging opening 302 therein. The exterior surface of the insert1404 engages the interior surface of the openings 1402 to preventrotation of the insert 1404 in the opening 1402. The engagementmechanism 1406 may be splines, key and keyway, friction fit, orotherwise. If splines or a key and keyway are used, such can beconfigured to enable the insert 1404 to be inserted with the shaftengaging opening 302 oriented in varying relation to the longitudinalaxis of the lock plate ]400 b. For example, the engagement mechanism]406 may allow the shaft engaging opening 302 to be changeablypositioned to substantially align a flat surface of the drive shaftsubstantially parallel to the longitudinal axis of the lock plate 1400 bor at an angle to the longitudinal axis of the lock plate 1400 b. Onecommon spline configuration would allow the shaft engaging opening 302to be rotated in 12 degree increments relative to the lock plate 1400 b.

Lock plate 1400 b is also provided with protrusions 1408 adapted toengage an interior of an opening (such as opening 204 of FIG. 15A) andsubstantially center the shaft engaging opening 302 over the opening oranother opening. The protrusions 1408 can also align the lock plate 1400b in relation to the construction set component, so for example, edgesof both the lock plate 1400 b and construction set component align. Theprotrusions 1408 reside about openings 1402. At least one protrusion1408 can be configured to prevent rotation of the lock plate 1400 b inrelation to another construction set component when received in anopening thereof.

The lock plate 1400 b is provided with demarcations 1410, formed by anindentation, notch, perforation, printed mark or otherwise, that defineadjacent segments 1412 of the bearing plate 1400 b. The demarcations1410 additionally facilitate reconfiguration of the bearing plate 1400b, for example, by indicating where the bearing plate 1400 b can be bentor cut, reducing the strength of the bearing plate 1400 b to facilitatebending or cutting and/or substantially preventing formation of sharpcorners as discussed above with reference to other construction setcomponents.

As shown in FIG. 14C, openings 1402 in either lock plate 1400 a and 1400b may be spaced in multiples of the spacings between openings 204 ofother components of the construction set, and such that when the lockplate 1400 a or 1400 b is affixed to another component with fastenersthrough openings 1402, the shaft engaging opening 302 is substantiallycentered over an opening 204. Additionally, the lock plate 1400 a and1400 b may include chamfers 206 to substantially eliminate sharp cornersto prevent injury to a user.

The lock plate 1400 a or 1400 b may be composed of material that isharder than that of the drive shaft 1302 to prevent wear to the lockplate 1400 a or 1400 b or softer than the drive shaft 1302 to preventwear to the shaft. Furthermore, the lock plate 1400 a or 1400 b may havea height dimension that is less than or equal to the height dimension ofa bar 200 (FIG. 2A), so that when the lock plate 1400 a or 1400 b isaffixed to the bar 200 or other similar component, the lock plate 1400 aor 1400 b does not substantially extend past the edges of the bar 200.Additionally, such a height dimension can correspond to the dimension ofthe segments 201 (for example FIG. 3A) of the construction setcomponents. Therefore, when the lock plate 1400 a or 1400 b is affixedto plate, such as plate 300 of FIG. 3A, it does not substantially extendpast the boundaries of the segments or interfere with adjacent openings,such as openings 204.

FIGS. 15A and 15B illustrate an exemplary configuration 1500 a and 1500b of the lock plate 1400 of FIG. 14 being coupled to the bar 200 of FIG.2A and shaft 1302 of FIG. 13. The lock plate 1400 may be coupled to thebar 200 via the openings 1404 of the lock plate 1400 being aligned withthe openings 204 of the bar 200 and fastening the lock plate 1400 andbar 200 with fasteners 1002 and lock nuts 1502. At least one of theopenings 1402 is to be aligned with one of the openings 204 to enablethe drive shaft 1302 to extend through the openings 1402 and 204. Thelock plate 1400 engages the drive shaft 1302 by the opening 1402 fixedlyengaging the drive shaft 1302 so that the coupling of the lock plate1400 to the bar 200 rotates the bar 200 as the lock plate 1400 isrotated by the drive shaft 1302. Additionally, the lock plate 1400provides structural support at the rotation junction of the shaft to thebar 200. It should be understood that the lock plate 1400 may be coupledto other components of the construction set having openings that alignto the openings 1404 and 1402 of the lock plate 1400. It should furtherbe understood that the lock plate 1400 may be sized and shapeddifferently to be in accordance with other components of theconstruction set and provide for the same functionality (i.e., to enablerotation or translation of construction set components).

FIG. 15B shows a configuration 1500 b of the lock plate 1400 beingcoupled to the bar 200 via the fasteners 1002 so as to enable the driveshaft 1302 to drive the bar 200 in a rotatable manner. As the driveshaft 1302 is rotated manually via a crank (not shown) orelectromechanical drive (e.g., motor) (not shown), the lock plate 1400,being secured to the bar 200 via the fasteners 1002, causes the bar 200to rotate.

FIG. 16A is an exemplary bearing or bushing plate 1600 a for use inconstructing a user-definable apparatus 100, such as that FIG. 1. FIG.16A is a front view. The appearance of the bottom surface may besubstantially the same. The bearing plate 1600 a includes at least onebearing opening 1602 disposed between openings 204 located towards eachend of the bearing plate 1600 a. The bearing opening(s) 1602 may besubstantially circular to support and allow a shaft 1302 to rotatefreely. The openings 204 may be shaped and spaced substantially similarto the openings of other components, such as the bar 200 of theconstruction set, to enable the bearing plate to be coupled thereto. Anexemplary bearing plate 1600 has round bearing openings 1602 thatclosely receive and support the drive shaft 1302 for smooth rotationtherein, in contrast to the less smooth rotation provided by otheropenings that are not dimensioned to closely receive the drive shaft1302. The bearing openings 1602 can be configured to substantiallyprevent contact of the drive shaft 1302 with an interior of an opening,such as opening 204, that is substantially aligned with the bearingopening 1602. Furthermore, the bearing openings 1602 can be configuredto allow a desirable degree of misalignment between the longitudinalaxis of the drive shaft 1302 and the central axis of the bearing opening1602.

FIGS. 16B-16C provide another exemplary bearing plate 1600 b thatinclude multiple openings 1606 extending through the bearing plate 1600b. Each of the openings 1606 are sized both to receive a fastener (e.g.,fastener 1002 of FIG. 17A) and to receive and support a drive shaft(e.g., drive shaft 1302 of FIG. 17A). Raised portions 1604 may includeopenings 1606 that may be disposed in relation to openings 204 of othercomponents of the construction set. Each opening includes sidewalls thatmayor may not be threaded to allow a fastening component to secure thebearing plate 1600 b to another component of the construction set. Tosimplify alignment and fastening of the bearing plate 1600 b to anothercomponent of the construction set, protrusions 1608 extending from thebottom of the bearing plate 1600 b may be provided. The protrusions 1608are configured to engage the interior of openings, such as openings 204,of other construction set components to align openings 1606 tosubstantially coincide and, in an exemplary embodiment, be centeredtherewith. Further, the protrusions 1608 may further engage an interiorof an opening to prevent rotation of the bearing plate 1600 b withrespect to the opening and the component to which the bearing plate 1600b is secured. The bearing plate 1600 b may be composed of plastic orother material having a hardness index value lower than the hardnessindex value of the drive shaft 1302 to reduce wear to the drive shaft1302 during rotation. The bearing plate 1600 b is provided withdemarcations 1610, formed by an indentation, notch, perforation, printedmark or otherwise, that define adjacent segments 1612 of the bearingplate 1600 b. The demarcations 1610 additionally facilitatereconfiguration of the bearing plate 1600 b, for example, by indicatingwhere the bearing plate 1600 b can be bent or cut, reducing the strengthof the bearing plate 1600 b to facilitate bending or cutting, and/orsubstantially preventing formation of sharp corners as discussed abovewith reference to other construction set components. It should beunderstood that the bearing plates 1600 a and 1600 b may be shapeddifferent to conform to other components of the construction set andperform substantially the same function.

FIGS. 17 A and 17B illustrate exemplary configurations 1700 a and 1700 bof the bearing plate 1600 a as coupled to the bar 200. The openings 204of the bearing plate 1600 a are spaced in multiple increments of thespacing between the openings 204 of the bar 200 and the bearing opening1602 is disposed between the openings 204 and aligned with the opening204 of the bar 200 to enable the drive shaft 1302 to extend through theopening 1602 of the bearing plate 1600 a through the opening 204 of thebar 200. It should be understood that the openings 204 and 1602 of thebearing plate 1600 a may also be designed to align with openings ofother components of the construction set. Fasteners 1002 and 1502 may beutilized to secure or couple the bearing plate 1600 s to the bar 200.The bearing plate 1600 a may be composed of metal or plastic. In thecase of a metal bearing plate 1600 a, the hardness index of the metalmay be higher than that of the drive shaft 1302 so as to substantiallyavoid wear to the bearing plate 1600 a as the drive shaft 1302 may bereplaced, according to the principles of the present invention.Alternatively, the bearing plate 1302 may be composed of plastic havinga lower index of hardness than the drive shaft 1302 so as to preventwear to the shaft.

FIGS. 18A and 18B are illustrations of the left and right side of awheel 1800, respectively, having hubs 1802 a and 1802 b (collectively1802) extending therethrough for use in constructing user-definableapparatus, such as that of FIG. 1. As shown in FIG. 18A, the hub 1802 aincludes an opening 1804 a centrally disposed. A tire 1806 composed offoam or other material may be disposed on and frictionally engage thehub 1802. FIG. 18B shows the hub 1802 b having an opening 1804 b that issubstantially square to engage a non-circular shaft and prevent rotationthereof relative to the wheel 1800. Alternatively, the opening may haveany other non-circular or polygonal shape to engage a non-circularshaft. Each of the hubs 1802 have coupling elements (not shown) operableto secure or fasten each hub 1802 a and 1802 b to one another to formthe wheel 1800. Alternatively, the hubs 1802 a and 1802 b may be bondedtogether, for example, with adhesive.

In operation, the opening 1804 a has a larger minimum dimension than thelargest diagonal dimension of the opening 1804 b so that the drive shaft1302 may extend through the opening 1804 a without obstruction. Theopening 1804 b may be configured to frictionally retain the drive shaft1302, for example, by having ribs or other elastically compressiblestructure disposed on the internal surface to compress around the driveshaft 1302. The hub 1802 may be composed of a thermoplastic material.The wheel 1800 may provide a rotational motion for a structure to bemoved by a motor coupled to a shaft engaging the opening 1804 b, asunderstood in the art. Alternatively, the wheel 1800 may providerotational motion for other functionality for user-definable structure.For example, the wheel 1800 may be utilized to translate sheets ofpaper.

FIGS. 19A and 19B are illustrations of an exemplary roller configuration1900 for use in constructing a user-definable apparatus, such as that ofFIG. 1. A roller 1902 is designed to receive the drive shaft 1302axially through the center of the roller 1902 and to frictionally engagethe drive shaft 1302 therein. The roller 1902 may be composed of acompressible foam rubber or other resilient material. A plastic core1904 may be adapted to receive the drive shaft 1302 and support theroller 1902 on the outside of the plastic core 1904. The plastic core1904 may form a hub at the respective ends of the roller 1902. Inoperation. upon turning of the drive shaft 1302, the roller 1902 turnsin relation to the rotation of the drive shaft 1302. The roller 1902 maybe utilized for, among other purposes, picking up balls or other objectsor equipment that may be desired to be collected by an electromechanicalor robotic device constructed using the component of the constructionset by a user.

FIGS. 20A-20C illustrate an exemplary sprocket or gear 2000 having acircular frame 2001 with a plurality of teeth 2002 extending radiallyfrom the circumference of the frame 2001. As shown in FIG. 20A, a hub2004 is coupled to and disposed substantially in the center of thecircular frame 2001 as shown in FIG. 20B. The hub 2004 further extendsaxially from the center of the frame 2001. An opening 2006 is disposedin the center of the circular frame 2001 that is shaped to frictionallyretain the drive shaft 1302. As shown, the opening 2006 is substantiallysquare, but other non-circular shapes may be utilized depending on theshape and/or dimensions of the drive shaft 1302. The opening 2006 mayinclude compressible ribs (not shown) extending axially along theinternal surfaces to frictionally engage the drive shaft 1302. Othercompressible structures may be utilized to frictionally retain the driveshaft 1302 according to the principles of the present invention. Thematerial of the sprocket may be of a self-lubricating thermoplastic, butother materials may also be utilized. The diameter of the circular frame2001 may be of any size to enable a user to construct a structure toperform certain operations, such as increasing or decreasing rotationalvelocity via a gear train by having different gear ratios. Additionally,the number and size of the teeth 2002 may be varied for design purposes.

FIGS. 21A and 21B illustrate respective exemplary side and top portionsof a chain 2100 for use with the sprockets 2000 of the construction set.The chain 2100 had the plurality of master chain links 2102 that areinterchangeably attached, one link to another, such that to remove thechain link 2102, one may twist the chain or otherwise forcefullyseparate the desired chain link 2102. It should be understood that thechain 2100 may be any predetermined length and allow for a user tochange the length by removing chain links 2102. The chain 2100 may becomposed of any material. In one embodiment, the chain 2100 is composedof thermoplastics to match the material of the sprockets 2000, if formedof thermoplastic material. The center-to-center distance (d) between thechain links 2102 is set such that the teeth 2002 of the sprockets 2000readily fit between each link 2102 of the chain 2100 and successivelymove links over the teeth 2002 of the sprocket 2000 as the chain moves.

FIG. 22 is an exemplary configuration of sprockets 2000 being coupledvia the chain 2100. As shown, the sprockets 2000 may allow one sprocket2000 to be driven by a shaft 1302 extending through the opening 2006. Inone embodiment, the drive shaft 1302 may be driven by a motor (notshown). Alternatively, the shaft may be driven by a crank operated by auser as understood in the art. Still yet, rather than using the chain2100, the sprockets 2000 may be engaged directly via the teeth 2002 sothat a sprocket 2000 being driven by a shaft to translate the rotationinto the second sprocket 2000. It should be understood that otherconfigurations for driving gears of the same or different sizes may beutilized in accordance with the principles of the present invention asunderstood in the art. The sprockets 2000 may be supported from a driveshaft to the bar-slide angle segment 603 b via the slot opening 608 b.By fastening the sprockets 2000 in the slot opening 608 b or anotheropening in the same or different component that provides for continuousadjustment, tension of the chain 2100 may be adjusted by sliding one orboth sprockets 2000 that engage the chain 2100.

FIG. 23 is an illustration of an exemplary configuration 2300 ofmultiple bars 200 of FIG. 2A being spaced by spacers 2302 for use inconstructing a user-definable apparatus 100, such as that of FIG. 1. Thespacers 2302, generally known as stand-offs, are operable to providestructural support for mechanical components, such as the bars 200,plates 300 and 500, and other components of the construction set. Itshould be understood that the spacers 2302 may be utilized in aconstruction set that does not provide components being designed to bealterable.

The spacers 2302 are shown to be hexagonal in shape and have threadedopenings (not shown) on each end of the spacers 2302 extending axiallyinto the spacers 2302. The threaded openings enable fasteners 1002, suchas screws, bolts, and the like, to fasten the spacers 2302 withcomponents of the construction set having openings (e.g., openings 204).Screws, such as hex screws, may be utilized to secure anotherconstruction set component, such as the bar 200, to the threaded spacer2302. The spacers 2302 provide for increased user-design capability andvariability of structures using the components of the construction set.The spacers 2302 provide for vertical (z-plane) expansion andconstruction. When multiple spacers 2302 are used to join constructionset components in a configuration similar to that in FIG. 23,significantly strong and light structures are formed. Additionally,multiple sized spacers 2302 may be included in the construction set toprovide additional variability in the design of structures. The spacers2302 may be off-the-shelf components having openings with threads thatare sized to receive fasteners for securing the spacers 2302 to othercomponents.

It should be understood that the square openings associated with themechanical components provide functional value, but also are ornamentalin nature. It should be appreciated that the geometry for the openings(e.g., opening 204) and shaft 1302 could have been another shape, suchas a hexagon, and produced the substantially same functionality. Bymaking the openings consistently substantially square (with roundedcorners), a separate and distinct ornamental value is established withconsumers of the construction set.

It should be understood that each of the construction set componentsdescribed herein can be formed from metal, plastic, or other material.Though not necessary for the concepts of this invention, the materialcan be plastically deformable without substantially breaking. One suchmaterial is cold rolled steel. If such a plastically deformable materialis desired, care must be taken when constructing the components fromplastic as most plastics that are rigid enough for forming constructionset components are not plastically deformable without substantiallybreaking.

Electromechanical Components

FIG. 24A illustrates an exemplary configuration 2400 a having anelectromechanical drive assembly 2402, including a motor, servo or otherdevice operable to translate electrical energy into motion 2403 (FIG.24B), for use in constructing a user-definable apparatus 100, such asthat of FIG. 1. The electromechanical drive assembly 2402 includes ahousing 2404 and a housing attachment 2406 that at least partiallysupport and encase the motor 2403. The housing attachment 2406 mayinclude stand-offs 2408 a and 2408 b that are operable to maintain acomponent (e.g., bar-slide angle portion 602 c) at a distance from afront surface 2409 of the housing attachment 2406. The stand-offs 2408 amay include a wing section and center section. Above the center section,a protrusion 2410 extends therefrom. The stand-off's 2408 may be spacedto correspond to the spacing between openings D. At least one protrusion2410 is sized and shaped to be closely received in an opening of acomponent, such as the slot opening 608 c of the bar-slide angle portion602 c or the opening 204 of another construction set component, andsubstantially prevent movement of the housing attachment 2406 inrelation to the component. The protrusion 2410 can have a non-circularexterior profile that engages a non-circular opening 204 or slot 608 cto prevent lateral movement and rotation about the axis of theprotrusion 2410. As shown in FIG. 24B, a flat edge of at least one ofthe protrusions 2410 engages a flat edge on an interior of the slotopening 608 c to align the electromechanical drive assembly 2402 inrelation to the slot opening 608 c.

As shown, the slot opening 608 c is substantially parallel to an edge ofthe bar-slide angle portion 602 c. When at least one of the protrusions2410 is received in the slot opening 608 c, an edge of the exterior ofthe electromechanical drive assembly 2402 is aligned with the edge ofthe bar-slide angle portion 602 c and the electromechanical driveassembly 2402 is substantially prevented from rotating in relation tothe bar-slide angle portion 602 c. Furthermore, the drive shaft 1302associated with the electromechanical drive assembly 2402 may besubstantially centered in the slot opening 608 c so as not tosubstantially contact the sides of the opening. The slot opening 608 ccan be provided in various positions to affect different alignment ofthe electromechanical drive assembly 2402 to the bar-slide angle portion602 c. Similar alignment and engagement can be achieved with holes 204and other components in the construction set. Likewise, in the case ofholes 204, the drive shaft 1302 and the protrusions 2410 can beconfigured to substantially center the drive shaft 1302 in a hole 204.

The stand-off 2408 b includes two wing sections that extend from thehousing attachment 2406. The stand-offs 2408 a and 2408 b may be spacedto have substantially the same spacing as openings of another componentof the construction set for alignment purposes. In one embodiment, thestand-offs 2408 a and/or the protrusions 2410 are internally threaded tothreadingly receive a fastener (e.g., fastener 1002 of FIG. 24B).Alternatively, the stand-offs 2408 a and/or the protrusions 2410 mayincorporate a male fastener 2418 (FIG. 24G) that extends outward fromthe housing attachment 2406. In another exemplary embodiment, thestand-offs 2408 a and/or protrusions 2410 can be integrated with afastening device, such as a snap mechanism 2420 (FIG. 24H) that deformsto insert through one or more openings in a construction set componentand snaps back to engage the construction set component to retain thehousing attachment 2406 in relation thereto. By mounting a bar-slideangle to the stand-offs 2408, the component to the stand-offs 2408 a and2408 b of the electromechanical drive assembly, alignment tolerances maybe relaxed.

The electromechanical drive assembly 2402 may include a socket or driveport 2412 operable to receive the drive shaft 1302 and rotate the driveshaft 1302 about an axis. The socket 2412 may be disposed toward an endof the electromechanical drive assembly to be compliant withconventional electromechanical drive assemblies having a gear system inthe center of electromechanical drive assembly. The socket 2412 may bespaced a distance D from an adjacent standoff 2408. The housingattachment 2406 and/or housing 2404 may be about at least part of thesocket 2412. FIG. 24A shows the socket 2412 substantially completelycontained within the housing 2404 and housing attachment 2406.Furthermore, one stand-off 2408 b may be positioned about the socket2412 and extend along an axis substantially parallel to the axis thatthe drive shaft 1302 is rotated about. The socket 2412 may be utilizedto releasably retain the drive shaft 1302 by having an interference fitor elastomeric sleeve that deforms about the drive shaft 1302 tofrictionally retain the drive shaft 1302 in the socket 2412 withouthaving to use a fastening component, such as a pin or screw, to maintainthe drive shaft 1302 in the socket 2412 of the electromechanical driveassembly 2402. Therefore, because the drive shaft 1302 is releasablyretained, one drive shaft 1302 may be interchanged with another,different drive shaft 1302.

The socket 2412 is non-circular and may be of any shape operable torotate a shaft. For example, the drive shaft 1302 as shown in FIG. 24Ahas a substantially square profile and the socket 2412 can have at leastone substantially planar surface operable to abut at least onesubstantially planar surface of the drive shaft 1302. The socket 2412 asshown in FIG. 24A has an internal square profile that receives thesquare external profile of the drive shaft 1302 and has foursubstantially planar surfaces that abut corresponding substantiallyplanar surfaces of the drive shaft 1302. By providing a socket 2412 thatabuts at least two surfaces of the drive shaft 1302, the socket 2412 cansupport the drive shaft 1302 in relation to the axis.

It is within the scope of the principles of the present invention thatthe socket 2412, rather than being substantially within the housing asdepicted in FIG. 24A. be provided in another component, for example inan end of a drive shaft that extends from the electromechanical driveassembly 2402.

FIG. 24B illustrates a configuration 2400 b of the electromechanicaldrive assembly 2402 engaging the bar-slide angle portion 602 c utilizingfasteners 1002 extending through and engaging the stand-offs 2408 a and2408 b extending from the housing attachment 2406. It should beunderstood that the housing attachment 2406 may be considered part ofthe housing 2404 of the electromechanical drive assembly 2402 whenconfigured thereto. The drive shaft 1302 extends through the slotopening 608 c of the bar-slide angle portion 602 c.

FIG. 24C is a top view of the electromechanical drive assembly 2402. Asshown, the stand-offs 2408 a and 2408 b are spaced at regular intervalsfor being coupled to components (e.g., bar 200) having openings atregular intervals. The stand-offs 2408 a each include substantiallysquare protrusions 2410 having an outer surface operable to engage innersurface of an opening of a component (e.g., opening 204 of bar 200). Thestand-offs 2408 further include an opening 2416 extending radiallytherein. The openings 2416 may include threads to enable a fastener toscrew into the opening 2416. As shown, the socket 2412 includes asubstantially square profiled opening 2414 having ribs 2418 beingelastically compressible extending axially along the inside surface ofthe opening 2414. It should be understood that the opening 2414 may havea profile other than square that engages a non-circular shaft for driveor moving a component of the construction set. As shown in FIG. 24D, theopening 2414 of the socket 2412 is shown to have the ribs 2418 extendingaxially into the socket to elastomerically and frictionally retain thedrive shaft 1302. Other elastically deformable structures alternativelymay be utilized.

FIG. 24E is an exemplary housing attachment 2406 that may be conformedto engage an existing housing, such as the housing 2404, or otherhousing attachment. The housing attachment 2406 is shown to have thestand-offs 2408 a and 2408 b and protrusions 2410 that are utilized toalign the electromechanical drive assembly 2402 to a component of theconstruction set.

FIG. 24F illustrates an exemplary housing attachment 2406 that may beutilized to be coupled to an electromechanical drive assembly 2402.Manufacturers of an electromechanical drive assembly may utilize thehousing attachment 2406 by attaching the housing attachment 2406 to theelectrochemical drive assembly to configure an existingelectromechanical drive assembly design or a new electromechanical drivedesign for use in a construction set.

FIG. 24I illustrates another configuration 2400 f of theelectromechanical drive assembly 2402 engaged with the angle gusset 700.As shown, the protrusions 2410 extend into the slot opening 708 foraligning the electromechanical drive assembly 2402 with the angle gusset700. The protrusions 2410 may frictionally fit the slot opening 708 tosimplify construction.

FIG. 25 is an exemplary flow chart 2500 for configuring the housing 2404having aperture engagement member(s} for example, protrusions 2410, suchas that shown in FIG. 24A, with a component of the construction set. Theprocess starts at step 2502. At step 2504, a housing body havingconstruction set component aperture engagement member(s) is received. Inone embodiment, the housing body is a housing attachment configured tobe affixed to an existing housing body. At step 2506, the housing bodyreceived is affixed to an electromechanical drive assembly. In oneembodiment, the electromechanical drive assembly includes a socket asshown in FIGS. 24A-24I. Alternatively, the electromechanical driveassembly may be an existing electromechanical drive assembly configuredto be utilized as a servo or motor and having a male coupling elementfor a shaft to engage the electromechanical drive assembly. The motormay be a direct current (DC) motor as understood in the art. The housingattachment may be affixed by utilizing an adhesive or mechanicalcoupling component. In the case of the electromechanical drive assemblyhaving a shaft that is substantially permanently coupled to theelectromechanical drive assembly, an element extending from or fastenedto the shaft may be removed for the housing body to be coupled to theelectromechanical drive assembly. By attaching or affixing the housingbody having at least one component aperture engagement member, such as aprotrusion operable to engage an opening of a component of theconstruction set, engaging of the electromechanical drive assembly tocomponents of the construction set may be substantially easier thanutilizing an existing housing of the electromechanical drive assembly.The process ends at step 2508.

FIG. 26 is an exemplary block diagram 2600 providing an electricalarchitecture for controlling speed and direction of an electromechanicaldrive for use in constructing an electromechanical structure fromcomponents of a construction set. A power supply 2602 is coupled to amain controller 2604 for providing power thereto. An H-bridge controller2606 is electrically coupled to the main controller 2604 and operable todrive an electromechanical drive 2608, such as a motor. A currentlimiter 2610 may be thermally coupled to the electromechanical drive2608 and electrically coupled to the H-bridge controller 2606. A signalconditioning and I/O protection circuit 2612 may be coupled to the maincontroller 2604 and be operable to condition signals being input to themain controller 2604.

A power input device 2614 may be utilized to provide power to the powersupply 2402 and current limiter 2610. The power input device 2614 may bea battery or transformer if receiving power from an external source. Thepower supply is utilized to drive the main controller 2604, whichreceives input via the signal condition and I/O protection circuit 2612based on control input signals 2616 received from a remote controller(not shown) as understood in the art. In one embodiment, the remotecontroller may utilize radio frequency signals. Alternatively, theremote controller may utilize infrared or- other types of communicationsignals. By utilizing a remote control, an apparatus may be considered aremotely piloted vehicle. The signal condition and I/O protectioncircuitry 2612 may be utilized to condition the control input signal2616 as understood in the art. The main controller 2604 may receive theconditioned control input signals 2617 and produce control signals 2618that are operable to be utilized for controlling the electromechanicaldrive 2608 at variable speeds and directions. The H-bridge controller2606 receives the control signals 2618 and drives the electromechanicaldrive 2608 with a drive signal 2620 to drive the electromechanical drive2608.

The current limiter 2610 operates to limit the voltage and/or current tothe electromechanical drive 2608 if the current being delivered to theelectromechanical drive 2608 from the H-bridge controller 2606 exceeds athreshold value or the temperature of the electromechanical drive 2608exceeds a threshold value. In one embodiment, the current limiter 2610is electrically coupled in series to the power terminals 2704 of theelectromechanical drive 2608 and thermally coupled to the powerterminals (see FIG. 27) to sense both the current and the temperature ofthe electromechanical drive 2608 to limit the current being deliveredfrom the H-bridge controller 2606 to the electromechanical drive 2608 bylimiting the current through the current limiter 2610. External heatingfrom the motor also causes the current limiter 2610 to limit current,and, thus, power being delivered to the electromechanical drive 2608.Reducing power to the electromechanical drive 2608 allows for cooling,which, in turn, causes the current limiter 2610 to stop limiting thecurrent.

This current limiting is effective to maintaining operation of theelectromechanical assembly 2402 because if too much current is suppliedto the motor, such as may be produced by the electromechanical structurein which the electromechanical drive 2608 is operating under a heavyload and/or stall condition, the windings of the electromechanical drive2608 tend to melt. If the windings melt, the electromechanical drive2608 becomes dysfunctional or simply breaks.

FIG. 27 A is an exemplary schematic 2700 of the variable speed anddirection control circuit provided by the block diagram 2600 of FIG. 26.The power supply 2602 may be configured to receive battery power orpower from another source and regulate the power using a regulator VIoperable to regulate the voltage provided to the main controller 2604 asunderstood in the art. One such regulator is an LM78Lxx seriesregulator. A header H1 may receive control input signals 2616 thatinclude battery power BATT, commands Sig1 and Sig2 to control operationof the electromechanical drive 2608, and ground GND. The control inputsignals 2616 are received and conditioned by the signals conditioningand I/O protection circuit 2612, which may include signal conditioningelectrical components operable to protect the main controller 2604 fromreceiving noisy signals and/or voltage or current spikes as understoodin the art.

The main controller 2604, which includes a processor U2, receives theconditioned control inputs 2612 and generates the control signals 2618based on the conditioned control inputs 2612. In one embodiment, theprocessor U2 may be a microcontroller PIC12Cxxx, that executes softwareoperable to receive the control input signals 2616 and generate controlsignals 2618 that may include a pulse width modulated (PWM) signal tocontrol the electromechanical drive 2608 at a variable speed within arange of speeds. TABLE 1 is an exemplary table that describes controlinput signals 2616 and the resulting control signals 2618 generated bythe main controller 2604 for control of the electromechanical drive 2608in relay mode, which includes control of the electromechanical drive2608 in neutral, full forward, and full reverse (i.e., without variablespeed control).

TABLE 1 Main Controller Processing Results in Relay Mode INPUTS OUTPUTSSig1 Sig2 STATE AH BH AL BL L L Neutral L L L L H H Neutral L L L L L HFull Fwd H L L H H L Full Rev L H H L

TABLE 2 is an exemplary chart describing operation of the maincontroller 2604 operating to provide variable speed and directioncontrol utilizing the H-bridge controller 2606 to drive theelectromechanical drive 2608. As shown, the states include neutral,forward, full forward, reverse, and full reverse. The inputs (i.e., AH,BH, AL, and BL) may have the control signals 2618 generated by the maincontroller 2604. There are five different states, neutral, forward, fullforward, reverse, and full reverse. In one embodiment, to drive theelectromechanical drive 2608 in variable speed mode, a chopping or pulsewidth modulated signal is applied to the H-bridge controller 2606 with aduty cycle proportional to the desired speed. The chopping signal may beapplied to either the high or low side terminals of the H-bridgecontroller 2606.

TABLE 2 Main Controller Processing Results in Variable Speed ControlMode INPUTS OUTPUTS AH BH AL BL STATE Mot (+) Mot (−) L L L L NEUTRAL LL H L L Chop FWD Chop L H L L H FULL FWD H L L H Chop L REV Chop H L H HL FULL REV L H

The H-bridge controller 2606 may include an H-bridge MOSFETconfiguration and/or other components and configurations as understoodin the art to control the rate of speed and direction of theelectromechanical drive 2608. In one embodiment, the H-bridge controller2606 may utilize a VN770 component produced by STMicroelectronics™Corporation. The H-bridge controller 2606 may receive power from thebattery via the current limiter 2610. The current limiter 2610 uses aresettable electronic device U4. In one embodiment, the resettableelectronic device U4 is a miniSMDC020 polyswitch surface-mount,resettable device produced by Raychem™ Corporation that operates asdrive protection for the H-bridge controller 2606 and electromechanicaldrive 2608. One type of resettable electronic device suitable for use inlimiting current based on temperature is generally known as a PTCcurrent limiter.

The principles of the present invention provide for the controller 102to include both a receiver and transmitter for two way communication ofinformation between the controller 102 and another electronic device,such as a remote control or data acquisition device. In one embodiment,the information being transmitted from the controller 102 may betelemetry data corresponding to data measured from sensors or computedby the main controller 2604 or other processor. The telemetry data maybe utilized to remotely monitor operation of the remotely pilotedvehicle. For example, the telemetry data may include informationrelating to power, battery charge, motor angles, or other kinematic orelectrical component operation. The telemetry data may be displayedusing an LED, LCD, monitor, or otherwise to enable the user to remotelymonitor the operation of the remotely piloted vehicle. It should beunderstood that the remotely piloted vehicle may be autonomous tooperate at least partially without remote user input. Accordingly, theuser may construct a robot as understood in the art and utilize awireless communication link for communicating information to and fromthe robot.

FIG. 27B is an exemplary mechanical schematic of a printed circuit board2702 for limiting current to the electromechanical drive based on anover-current and/or over-temperature condition thereof. As shown, thelayout of printed circuit board 2702 include power terminals 2704 forthe electromechanical drive 2608. Two thermal links 2613 couple thepower terminals 2704 to pads 2706 that the current limiter 2610 ismounted. The thermal links 2613 may be composed of fiberglass, copper,metal, or any combination of printed circuit board material fortransferring heat from the power terminals 2704 to the current limiter2610.

FIG. 28 is an exemplary flow diagram 2800 for controlling theelectromechanical drive 2608 of the electromechanical drive assembly2402 of FIG. 24A for an electromechanical structure constructedutilizing the construction set. The process starts at step 2802. At step2804, a control input signal 2616 is received for controlling theelectromechanical drive 2608 at a variable speed and direction. At step2806, a control signals 2618 corresponding to the variable speed anddirection is generated within the housing 2404 of the electromechanicaldrive assembly 2402. The control signal 2618 is received within thehousing 2404 at step 2808 and a drive signal 2620 is generated withinthe housing 2404 based on the control signal 2618 at step 2810. At step2812, the drive signal 2620 is applied to the electromechanical drive2608 to control variable speed and direction to move a component of theconstruction set. The process ends at step 2814.

FIG. 29 is an exemplary flow chart 2900 for converting a non-variablespeed electromechanical drive assembly to an electromechanical driveassembly 2402 for use with a construction set for constructing anelectromechanical apparatus. Because there are many existing servosand/or motors that are produced for builders of model electromechanicalstructures (e.g., model airplanes, vehicles, etc.), the cost of theexisting servos and/or motors is relatively low. However, these existingservos and/or motors are limited in that they are do not provide forvariable speed control without having a separate variable speedcontroller, such as an H-controller. Therefore, the non-variable speedservos and/or motors provide for a viable commercial solution to beutilized for use in the construction set according to the principles ofthe present invention with some modifications. The modifications mayinclude converting the non-variable speed electromechanical driveassembly to enable variable speed and direction. As previouslydiscussed, other modifications may include affixing the housingattachment 2406 to an existing housing of the non-variable speedelectromechanical drive assembly. Still yet, the male output assemblymay be converted to include the female output socket 2412.

The manufacturing process for converting a non-variable speedelectromechanical drive assembly to an electromechanical drive assembly2402 starts at step 2902. At step 2904, a non-variable speedelectromechanical drive assembly is received. An H-bridge circuit iselectrically connected to the non-variable speed electromechanical driveassembly to enable variable-speed control of the electromechanical driveoperating therein at step 2906. The process ends at step 2908.

FIGS. 30A and 30B illustrate an exemplary user-defined apparatus 100that is electromechanical, without and with the controller 102 forcontrolling operation of the apparatus via motors 104 of FIG. 24A. Asshown, the electromechanical user defined apparatus 100 includes amotherboard 3002 for use in mounting, powering, and operatingelectronics as understood in the art. The motherboard 3002 includes twoheaders 3004 that the controller 102 may be mounted. By utilizing amotherboard 3002 with headers 3004 operable to mount and power thecontroller 102, a user may construct multiple electromechanicalstructures with motherboard 3002 and utilize a single controller 102,which may be more expensive than the mechanical components, to operateand control the apparatus 100. As shown on FIG. 30B, the controller 102may be installed onto the user defined apparatus 100 by simplyconnecting the controller 102 to the headers 3004, thereby allowing theuser to control the user defined apparatus 100 via a remote, wirelesscontroller.

Tools

The construction set may come complete with tools that may be utilizedfor altering, including resizing, reshaping, and/or reconfiguringmechanical components that may be utilized to form a user-definablestructure. As discussed with regard to the bar 200, the bar 200 may bereshaped by being bent or cut to provide different components (i.e., acomponent having a different length and shape). Additionally, becausethe mechanical components are coupled to one another, tools providedwith the construction component may be utilized to perform the couplingoperations.

FIG. 31 illustrates an exemplary break press clamp 3100 for use inreconfiguring a component designed to be alterable (e.g., bar 200) foruse in constructing a user-definable apparatus 100, such as that ofFIG. 1. The break press clamp 3100 includes a bottom portion 3102 and atop portion 3104. The bottom portion 3102 includes a substantiallyV-shaped notch 3106 spanning laterally across the bottom portion 3102.The top portion 3108 includes a substantially V-shaped portion 3108extending from the top portion 3104 that is adapted to fit the V-shapednotch 3106 of the bottom portion 3102 of the break press clamp 3100.Adjacent the V-shaped notch 3106 of the bottom portion 3102 are orifices3110 that are aligned with openings 3112 disposed on each side of theV-shaped portion 3108 of the top portion 3104 of the break press 3100.Both the top and bottom portions 3104 and 3102 may be composed of 1018steel or a suitable hard material as understood in the art to be harderthan the components being altered. The V-shaped portion 3108 of the topportion 3104 is adapted to provide a cutting surface, such that whenmechanical components designed to be alterable (e.g., plate 300) areplaced between the extending V-shaped portion 3108 of the top portion3104 and the V-shaped notch 3106 of the bottom portion 3102 of the breakpress 3100, a force may be translated directly onto the surface of themechanical component for use in cutting and/or bending.

Alignment posts 3114, optionally, may extend from the bottom portion3102 of the break press 3100 to facilitate alignment of the plate 300 orother component designed to be alterable. By engaging the openings 204with the alignment posts 3114, the indentations 208 or other demarcation(e.g., opening 302) may be aligned with the V-shaped portion 3108 foraltering (e.g., bending or cutting) of the plate 300 in relation to theindentations 208. In one embodiment, the alignment posts 3114 may bedisposed in a fixed position. Alternatively, the alignment posts 3114may be selectively moved to along the bottom portion 3102 of the breakpress 3100. While the use of alignment posts 3114 is useful foralignment of components designed to be alterable having openings, suchas opening 204, other alignment mechanisms may be utilized, such asstops, bars, protrusions, demarcations, retractable elements, insertableelements, etc. Also, such alignment posts 3114 allow the break press3100 to be used with other construction set components that are notdesigned to be alterable, but that also include openings, such asopenings 204, and thereby sever the component in a pre-determinedrelation to the openings. The V-shaped portion 3108 may optionally beconfigured to cut chamfers, curved or other additional shapes into thecomponent being altered, so that: for example, when severingconstruction set components that are not designed to be alterable,substantially no sharp corners are formed.

The aligned openings 3112 of the top portion 3104 and orifices 3110 ofthe bottom portion 3102 of the break press 3100 may be further adaptedto receive a screw therethrough; the orifices 3110 adapted tothreadingly engage the threads of the screws. To apply a desiredsevering or bending force, the screw inserted therein may be turned asufficient number of turns until the desired bend or sever is achieved.As shown, the plate 300 may be aligned such that the indentations 208are positioned along the V-shaped portion 3108 of the top portion 3104.When the top portion 3104 of the break press 3100 is pressed down intothe bottom portion 3102 (e.g., through the tightening of screws), theplate 300 is bent or severed substantially between the indentations 208.By aligning the openings 302 substantially between the indentations 208,the plate 300 may have reduced resistance to bending to make the bendingand/or severing easier and produce substantially no sharp edges if thesevering stops at an opening 302. The top portion 3104 or bottom portion3102 may have portions other than the V-shaped portions 3108 and 3106,respectively, to be provide for more severing or bending ability. Forexample, the V-shaped portion 3108 may have a rounded or squared bottomedge to provide for more bending ability.

Tools other than the break press 3100 may be utilized to bend and/orsever components designed to be alterable. For example, clippers,scissors, and the like may be used to cut along the axis extending fromthe indentations 208 and/or demarcations (e.g., indentations 208 andopenings 302) of the components designed to be alterable provided in theconstruction set.

Referring now to FIG. 32, there is shown a wrench 3200 specificallyadapted to manipulate mechanical components of the construction set. Thewrench has a first open end 3202 and a second closed end 3204, as domost wrenches known in the art. The open and closed ends 3202 and 3204of the wrench 3200 are sized for gripping components provided in theconstruction set, such as the spacers 2302, during construction of astructure. A plurality of openings 3206, which are for aestheticpurposes, may be provided between the ends 3202 and 3204 of the wrench3200, but also may be used to align the wrench 3200 with respect toother mechanical components having similar openings 3206. The wrench3200 may be composed of a suitably hard material, such that the hardnessof the wrench 3200 is greater than that of the mechanical componentsdesired to be manipulated.

To provide coupling means to the various mechanical components of thesystem it should be appreciated that miscellaneous coupling or fasteningcomponents, including screws, bolts, nuts, snaps, rivets, etc., may beincluded with the construction set to make prototyping and constructiona fast and easy process. Other fastening component variations mayinclude hexagonal screws, lock nuts, Teflon nuts, nylon lock nuts, andwashers. It should be understood that various fastener componentsaccomplishing the same function as these described may be suitablysubstituted and/or included. The various fastening or coupling membersmay be sized accordingly to mate with the various openings of thevarious mechanical components described herein.

Business Methodologies

FIG. 33 is an exemplary flow chart 3300 describing distribution ofcomplete construction sets having component(s) designed to be alterableand separate component(s) designed to be alterable for use in replacingthe alterable components as desired. The distribution process starts atstep 3302. At step 3304, the construction set including component(s)designed to be alterable to be configured into different component(s)are received. In one embodiment, the construction set is manufactured bya company and received by the shipping department for distributionpurposes. In another embodiment, a construction set enclosed in ashipping container (e.g., box) is received by a company from amanufacturer of the construction set ready for distribution. In yetanother embodiment, components of the construction set are received andprepared for distribution by a company. At step 3306, the constructionset is distributed. The distribution of the construction set may bedirect to consumers or via a distribution channel. In the case ofdistributing the construction set direct to consumers, stores, mailorder, network (e.g., the Internet) marketing, or other forms ofdirect-to-consumer marketing and selling practices as known in the artmay be utilized to distribute the construction. In the case ofdistributing the construction set via a distribution channel, sellingdirectly to distribution outlets, such as retail stores, wholesalestores, etc. may be performed. Additionally, distribution of theconstruction set to mail order catalogs, distributors, or other “middleman” operation may be utilized.

At step 3308, the component(s) designed to be alterable (e.g., bar 200)of the construction set may be made available to be distributed separatefrom the construction set for replacement purposes. In making availablethe component(s) designed to be alterable, consumers and/or distributionchannels may be notified of the availability of the component(s)designed to be alterable for purchasing. In one embodiment, thecomponent(s) are provided in separate containers (e.g., box, bag, etc.)and distributed via the distribution channel(s) that the constructionset is distributed. Alternatively, the component(s) and associatedprice(s) may be posted on a network or listed on a price sheet, catalog,flier, or other forms of notification to purchasers of the constructionset. By making available the component(s) designed to be alterable,users who consume or use the component(s) designed to be alterable maypurchase other ones to be used for constructing one or more structures.And, because the component(s) designed to be alterable may be altered toform different components, the user may construct structures of nearlyany shape and size to perform nearly any function desired by the user.

FIG. 34 is an exemplary flow diagram 3400 for teaching projectdevelopment lessons utilizing the construction set having componentsdesigned to be alterable, such as the bar of FIG. 2A, according to theprinciples of the present invention. The lessons may be meant to teachreal-world project development issues. Such real-world projectdevelopment issues may include design, manufacturing, cutting, wastemanagement, cost issues, inventory control, monitoring usage ofconsumable components, and other real-world issues that arise in projectdevelopment as experienced by engineers in industry.

The project development instruction starts at step 3402. At step 3404, arequirements specification may be provided to a project developer. Theproject developer may be a student, competitor, or other user who is toconstruct a user-definable structure that complies with the requirementsspecification utilizing the construction set having component(s)designed to be alterable. The requirements specification may be a formaldocument, non-formal document, or oral recitation of a function or actto be achieved by the user-definable structure. One exemplary functionmay be picking up balls and placing them in a basket.

At step 3406, the construction set having component(s) designed to bealterable may be provided to the project developer. In providing theconstruction set, a complete set may be provided. Alternatively,components from the construction set may be provided and the projectdeveloper may select the components desired to construct theuser-definable structure in accordance with the requirementsspecification. In designing the user-definable structure conforming tothe requirements specification, the project developer may generatedesign drawings depicting the structure prior to construction. Thedesign drawings may be provided to an instructor for review at step3408. At step 3410, the instructor may review and provide feedback onthe design drawings.

At step 3412, the user-definable structure designed to conform to therequirements specification may be received by the instructor. In oneembodiment, the instructor receives and grades the user-definablestructure based. on functionality, appearance, dimensions, operability,and/or other visual and functional aspects. Alternatively and/oradditionally, the user-definable structure may be received by theparticipation of the structure in an event, such as a contest, tooperate in accordance with the requirements specification. Based on theoperation of the user-definable structure in the event, the projectdeveloper may receive a score, grade, or other merit based value. Theprocess ends at step 3414.

In addition to teaching real-world problem solving as described inconnection with FIG. 34, the principles of the present invention may beused to further education of students with respect to the constructionof electrical, mechanical and electromechanical devices. To assist withteaching students, an instructor may utilize components of theconstruction set to develop a curriculum in various academic fields,such as science, mathematics, physics and the like. Based on thecomponents in the construction set, the curriculum may provideguidelines for developing mathematical, scientific or physic formulae tosatisfy a problem. Based on results of the calculations, the studentsmay select parts from the construction set as described in thecurriculum for accomplishing objectives in furtherance of solving theproblem. Instructions for building different structures may be providedin the curriculum. After selection of the components, the students maythen build the desired prototype and attempt to provide a workingsolution to the problem. If unsuccessful, the teacher may suggest otherformulae in accordance with the associated curriculum to developalternate solutions to the problem.

Use of a construction set provided in accordance with the invention alsocan be used in teaching material usage, inventory, and selection ofcomponents. By providing a set number of components within a kit, theuser may determine the optimum usage of the materials both in selectingthe proper component for the task and in altering components to produceadditional components. For example, the user may choose between using anexisting component or modifying other components to accomplish a giventask while weighing the need for a specific configuration against itsimpact on the inventory of similar component or other components thatare alterable to achieve the same task. Further, when altering acomponent, the user may learn to optimize usage of given component toachieve the desired configuration while at the same time minimizingwastage.

FIG. 35 is an exemplary embodiment for teaching production cycle projectdevelopment utilizing a construction set having at least oneconstruction set component designed to be alterable for constructing auser-definable apparatus 100, such as that of FIG. 1. The productioncycle teaching process starts at step 3502. At step 3504, instructionsmay be provided for constructing the user-definable apparatus includingat least one construction set component designed to be alterable. Theinstructions may include requirements to construct an apparatus toperform a particular task (e.g., picking up a ball). Alternativelyand/or additionally, the instructions may include specifications ofmaximum size and/or weight. It should be understood that otherinstructions may be provided to challenge the designer to be more orless creative in the process of designing the user-definable apparatus.A variety of project development activities may also be monitored. Suchproject development activities may include procurement, management ofmaterial, quality control, and time management. By monitoring theseactivities, feedback may be provided to enhance the real-world skills ofthe designer of the user-definable apparatus.

To allow the user-defined apparatus to be tested to predefinedspecifications, a test environment may be established at step 3506. Inone embodiment, the test environment may be formed on top of a desk ortable and optionally include other objects that the user-definedapparatus is to engage. Alternatively, the test environment may beformed on a floor. At step 3508, the user-defined apparatus may betested in the test environment to verify that the predefinedspecifications are satisfied. At step 3510, a determination is made asto whether the user-defined apparatus satisfies the predefinedspecifications. The predefined specifications may include time limits orefficiency for performing a task. The predefined specification also mayinclude size, weight, shape, creativeness, ingenuity, part count,modified component count, or other objective and subjective criteria.

At step 3512, it is determined if the user-defined apparatus satisfiedthe predefined specification. If the user-defined apparatus did notsatisfy the predefined specification, then at step 3514, time isallotted for the user-defined apparatus to be re-designed. Re-testing ofthe user-defined apparatus may be performed at step 3508 to determine ifthe re-design improved the user-defined apparatus with respect to thepredefined specification. If the user-defined apparatus satisfies thepredefined specification at step 3512, then the process ends at step3516.

The teaching of real world engineering is becoming more important.Engineers are required to juggle an enormous collection of design,safety, manufacturability, cost, technology, risk, and usabilityrequirements. In addition, the fabrication cycle of building a prototypeor production apparatus involves aspects of production tools andtechnology, operator training, parts inspection and rejection, and soon. The full set of these requirements is never fully understood even byexperienced engineers or project managers, however, the ability to lookat a variety of requirements that are often at odds with one another isstill to be taught.

College design competitions are designed to teach engineers tounderstand some of these issues. These competitions have a variety ofstyles and demand application engineering talents of the mechanical,electrical, and/or software designers to succeed. During the process,the engineers learn more than just engineering.

By incorporating aspects of design competitions with a construction setfor constructing a user-definable apparatus, the need for significantand detailed engineering talents can be eliminated, and the real worldaspects of problem solving can still be addressed. The designcompetition can now be taught at earlier educational levels. By studentsperforming the seemingly enjoyable task of building a robot to competeagainst others, a long list of problem solving, engineering, andproduction problems may be encountered.

The following is an exemplary list of the issues that may be experiencedand taught with the use of this method for teaching production cycleproject development. TABLE 3 shows major subjects that are addressed byteaching utilizing the principles of the present invention. These majortopics address a variety of management and planning issues that surroundan engineering development project that students may encounter in thereal world.

TABLE 3 Major Subjects Addressed by Teaching Product Cycle ProjectDevelopment Ida brainstorming Concept development and refinementPrototype design and fabrication Engineering (electrical, mechanical,and software System engineering Project management Cost managementProgram or product management Component fabrication Product assemblyProduct testing Product redesign and product improvement Productmaintenance and repair

TABLE 4 is an exemplary list of additional topics addressed by teachingthe product cycle project development using the construction set havingcomponents designed to be alterable for constructing a user-definableapparatus. The topics are relevant to students learning the details ofan engineering construction project.

TABLE 4 Additional Topics Addressed by Teaching Product Cycle ProjectDevelopment Time management Material usage Parts inspection andtolerances Parts scrapping and rebuilding How design affects assemblytime How design affects maintenance and repair Benefits of a simpledesign Problems with complex designs Manufacturing tool usage and safetyImportance of documentation and document control

As will be recognized by those skilled in the art, the innovativeconcepts described in the present application can be modified and variedover a wide range of applications. Accordingly, the scope of patentedsubject matter should not be limited to any of the specific exemplaryteachings discussed, but is instead defined by the following claims.

1-37. (canceled)
 38. A method for constructing a user-defined, electromechanical apparatus, the method comprising: coupling a first drive member to a socket of an electromechanical drive, the electromechanical drive operable to translate electrical energy into movement and operable to move the drive member coupled to the socket; and interchanging the first drive member with at least one other drive member.
 39. The method of claim 38 further comprising rotating at least one of the other drive members about an axis using the electromechanical drive.
 40. The method of claim 38 further comprising moving at least one of the other drive members coupled to the electromechanical drive using an H-bridge of the electromechanical drive.
 41. The method of claim 38 further comprising moving at least one of the other drive members coupled to the electromechanical drive at variable speeds using an H-bridge of the electromechanical drive.
 42. The method of claim 38 further comprising frictionally retaining the first drive member at least partially in the socket of the electromechanical drive.
 43. The method of claim 38 further comprising releasably retaining the first drive member at least partially in the socket of the electromechanical drive.
 44. The method of claim 38 further comprising elastomerically retaining the first drive member at least partially in the socket of electromechanical drive through one or more ribs of the socket.
 45. The method of claim 38 further comprising coupling a component of a construction set to a housing about at least a portion of the electromechanical drive.
 46. The method of claim 38 further comprising coupling a component of a construction set to the electromechanical drive.
 47. The method of claim 38 further comprising coupling a component of a construction set to at least one of the other drive members.
 48. The method of claim 47 further comprising moving the component using the electromechanical drive.
 49. The method of claim 38 wherein the electromechanical drive is a DC motor.
 50. A method for constructing a user-defined, electromechanical apparatus, the method comprising: coupling a drive member to an electromechanical drive such that the drive member is interchangeable with at least one other drive member; and moving the drive member with the electromechanical drive.
 51. The method of claim 50 further comprising coupling at least one component to the drive member.
 52. The method of claim 51 further comprising moving at least one of the components coupled to the drive member using the electromechanical drive.
 53. The method of claim 50 further comprising coupling at least one component to the electromechanical drive.
 54. The method of claim 50 further comprising replacing the drive member coupled to the electromechanical drive with at least one other drive member.
 55. A method for constructing a user-defined, electromechanical apparatus, the method comprising: coupling a first drive member to a socket of an electromechanical drive, the electromechanical drive operable to translate electrical energy into movement and operable to move a drive member coupled to the socket; removing the first drive member from the socket of the electromechanical drive; and coupling a second drive member to the socket of the electromechanical drive.
 56. The method of claim 55 further comprising rotating the second drive member using the electromechanical drive.
 57. The method of claim 55 further comprising: coupling at least one component to the second drive member; and moving at least one of the components coupled to the second drive member using the electromechanical drive. 